Method of producing opened fiber bundle, and method of producing cleaning member, apparatus which opens fiber bundle, and system which produces cleaning member

ABSTRACT

A method of producing an opened fiber bundle is in a space-saving manner. The method of continuously producing an opened fiber bundle for a cleaning member, includes the steps of (a 1 ) providing (i) first nip rolls, (ii) second nip rolls, (iii) third nip rolls, and (iv) an air feeder; (a 2 ) conveying a fiber bundle using the first nip rolls and the second nip rolls to apply a tensile force to the fiber bundle; (a 3 ) conveying the fiber bundle using the second nip rolls and the third nip rolls to relax the fiber bundle, thereby forming a belt-shaped fiber bundle; and (a 4 ) blowing air from the air feeder in a direction intersecting with the conveying direction of the first belt-shaped fiber bundle.

RELATED APPLICATIONS

The present application is based on, and claims priority from, JapaneseApplication Number 2012-289182, filed Dec. 29, 2012, the disclosure ofwhich is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to a method of producing an opened fiberbundle, a method of producing a cleaning member, an apparatus whichopens a fiber bundle, and a system which produces a cleaning member.

BACKGROUND ART

Various methods for opening a fiber bundle, particularly a bundle ofcrimped fibers for use in a brush part or the like of a cleaning memberhave been being considered.

For example, PTL 1 describes a method of opening continuous filaments,the method including transporting crimped tow by means of a plurality ofrolls; and applying a resistance on at least one side of the tow byslidingly contacting at least one sliding body onto the tow at betweenrolls, whereby continuous filaments stacked in a thickness direction ofthe tow are caused to sift in a transporting direction of the tow toopen the tow and to spread the continuous filaments in a width directionof the tow.

CITATIONS LIST Patent Literature

-   PTL 1 Japanese Unexamined Patent Publication No. 2002-069781

SUMMARY OF INVENTION Technical Problem

The method described in PTL 1 requires a plurality of sliding plates,which results in a larger opening apparatus, and thus it is difficult tominiaturize the apparatus for producing a cleaning member.

Thus it is an object of the present disclosure to provide a method ofproducing an opened fiber bundle in a more space-saving manner.

Solution to Problem

As a result of assiduous research intended to solve the problemsdescribed above, the present inventors have found a method ofcontinuously producing an opened fiber bundle for a cleaning member,comprising the steps of (a₁) providing (i) first nip rolls, (ii) secondnip rolls, which are disposed downstream from the first nip rolls andhave a faster peripheral velocity compared with the first nip rolls,(iii) third nip rolls, which are disposed downstream from the second niprolls and have a slower peripheral velocity compared with the second niprolls, and (iv) an air feeder which is disposed downstream from thesecond nip rolls; (a₂) conveying a fiber bundle using the first niprolls and the second nip rolls to apply a tensile force to the fiberbundle; (a₃) conveying the fiber bundle using the second nip rolls andthe third nip rolls to relax the fiber bundle, thereby forming abelt-shaped fiber bundle; and (a₄) blowing air from the air feeder in adirection intersecting with to the conveying direction of thebelt-shaped fiber bundle.

Effects of Invention

The method of producing an opened fiber bundle according to the presentdisclosure provide an effect of producing an opened fiber bundle in aspace-saving manner.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic view illustrating a method of producing an openedfiber bundle and/or an apparatus which opens a fiber bundle according toan embodiment of the present disclosure.

FIG. 2 illustrates a method of producing an opened fiber bundle and/oran apparatus which opens a fiber bundle according to another embodimentof the present disclosure.

FIG. 3 is an enlarged environmental perspective view of an openingfacilitator 115 illustrated in FIG. 2.

FIG. 4 is an enlarged environmental side view of the opening facilitator115 illustrated in FIG. 2.

FIG. 5 is a side view of an opening facilitator used in a method ofproducing an opened fiber bundle and/or an apparatus which opens a fiberbundle according to another embodiment of the present disclosure.

FIG. 6 illustrates a method of producing an opened fiber bundle and/oran apparatus which opens a fiber bundle according to still anotherembodiment of the present disclosure.

FIG. 7 is a perspective view of a widening member 201 as illustrated inFIG. 6 which the member 201 is widening a belt-shaped fiber bundle F′1in the width direction.

FIG. 8 illustrates a method of producing an opened fiber bundle and/oran apparatus which opens a fiber bundle according to still anotherembodiment of the present disclosure.

FIG. 9 is a schematic view of an apparatus which opens a fiber bundleand/or a system which produces a cleaning member according to anembodiment of the present disclosure.

FIG. 10 is an overall perspective view of a cleaning member 1 and ahandle 15.

FIG. 11 is a cross sectional view taken along the line XI-XI in FIG. 10.

FIG. 12 is a plan view of the cleaning member 1 in FIG. 10.

DESCRIPTION OF EMBODIMENTS

The method of producing an opened fiber bundle, the method of producinga cleaning member, the apparatus which opens a fiber bundle, and thesystem which produces a cleaning member according to the presentdisclosure will be described in detail.

<<Method of Producing Opened Fiber Bundle and Apparatus which OpensFiber Bundle>>

The method of continuously producing an opened fiber bundle for acleaning member according the present disclosure (hereinafter referredto as “method of producing an opened fiber bundle”) includes the stepsof:

(a₁) providing (i) first nip rolls, (ii) second nip rolls, which aredisposed downstream from the first nip rolls and have a fasterperipheral velocity compared with the first nip rolls, (iii) third niprolls, which are disposed downstream from the second nip rolls and havea slower peripheral velocity compared with the second nip rolls, and(iv) an air feeder which is disposed downstream from the second niprolls (hereinafter referred to as “step (a₁)”);

(a₂) conveying a fiber bundle using the first nip rolls and the secondnip rolls to apply a tensile force to the fiber bundle (hereinafterreferred to as “step (a₂)”);

(a₃) conveying the fiber bundle using the second nip rolls and the thirdnip rolls to relax the fiber bundle, thereby forming a belt-shaped fiberbundle (hereinafter referred to as “step (a₃)”); and (a₄) blowing airfrom the air feeder in a direction intersecting with the conveyingdirection (machine direction) of the belt-shaped fiber bundle(hereinafter referred to as “step (a₄)”).

The apparatus which opens a fiber bundle for a cleaning member accordingto the present disclosure (hereinafter referred to as “apparatus whichopens a fiber bundle”) includes:

first nip rolls,

second nip rolls, which are disposed downstream from the first niprolls, have a faster peripheral velocity compared with the first niprolls, and, together with the first nip rolls, convey the fiber bundleto apply a tensile force to the fiber bundle,

third nip rolls, which are disposed downstream from the second niprolls, have a slower peripheral velocity compared with the second niprolls, and, together with the second nip rolls, convey the fiber bundleto relax the fiber bundle, thereby forming a belt-shaped fiber bundle,and

an air feeder which is disposed downstream from the second nip rolls andblows air in a direction intersecting with the conveying direction ofthe belt-shaped fiber bundle.

The present disclosure will be described along with the method ofproducing an opened fiber bundle according to the present disclosure andwith reference to FIG. 1.

FIG. 1 is a schematic view illustrating a method of producing an openedfiber bundle and an apparatus which opens a fiber bundle according to anembodiment of the present disclosure.

[Step (a₁)]

FIG. 1 illustrates (i) first nip rolls 102, (ii) second nip rolls 106,which are disposed downstream from the first nip rolls 102 and have afaster peripheral velocity compared with the first nip rolls 102, (iii)third nip rolls 114, which are disposed downstream from the second niprolls 106 and have a slower peripheral velocity compared with the secondnip rolls 106, and (iv) an air feeder 108, which is disposed downstreamfrom the second nip rolls.

[Step (a₂)]

As illustrated in FIG. 1, a first fiber bundle F1 is drawn from acontainer (not illustrated) and conveyed onto the first nip rolls 102.The first nip rolls 102 rotate at a constant peripheral velocity V₁ toconvey the first fiber bundle F1 in the machine direction MD. The firstfiber bundle F1 runs through the first nip rolls 102 and then runsthrough tension rolls 104 to reach the second nip rolls 106.

The second nip rolls 106 are configured to have the peripheral velocityV₂ faster than the peripheral velocity V₁ of the first nip rolls 102.Such configuration allows a tensile force in the machine direction to beapplied to the first fiber bundle F1 between the first nip rolls 102 andthe second nip rolls 106. As a result, the first fiber bundle F1 isextended.

If the first fiber bundle F1 includes crimped fibers, the crimped fibersbefore the tensile force is applied are approximately uniformly crimpeddue to its production process, and thus the crimped fibers are lesslikely to unravel. Application of a tensile force to such fibers allowsthe crimps of the fibers to be temporarily extended, thereby reducingthe crimp degree.

The plurality of tension rolls 104 are preferably formed of, forexample, solid steel so that the rolls have a high mass. As substantialforce is required to rotate the tension rolls 104, the rate of movementof the first fiber bundle F1 conveyed from the first nip rolls 102 tothe second nip rolls 106 can be gradually increased, and thus thetensile force applied to the first fiber bundle F1 can be graduallyincreased.

The plurality of tension rolls 104 are disposed so that the distancebetween the first nip rolls 102 and the second nip rolls 106 isincreased, in order to gradually increase the tensile force applied tothe first fiber bundle F1.

A method of producing an opened fiber bundle and an apparatus whichopens a fiber bundle according to another embodiment of the presentdisclosure do not use the tension rolls.

[Step (a₃)]

The first fiber bundle F1 runs through the second nip rolls 106 and thenreach the third nip rolls 114 via the air feeder 108 and an oilapplicator 110. The third nip rolls 114 are configured to have theperipheral velocity V₃ slower than the peripheral velocity V2 of thesecond nip rolls 106. Thus, after the first fiber bundle F1 runs throughthe second nip rolls 106, the fibers of the first fiber bundle F1 areopened between the second nip rolls 106 and the third nip rolls 114because the tensile force is relieved, and the first fiber bundle F1 isfurther widened, thereby forming a first belt-shaped fiber bundle F′1.

The air feeder 108 will be described in “Step (a₄)” described below,while the oil applicator 110 will be described in “Other Steps”described below.

For the method of producing an opened fiber bundle, the method ofproducing a cleaning member, the apparatus which opens a fiber bundle,and the system which produces a cleaning member, “width direction”, asused herein, means a direction which is orthogonal to the machinedirection and is horizontal, unless otherwise indicated.

When the first fiber bundle F1 includes crimped fibers, relief of thetensile force allows the crimp of the crimped fibers to be recovered,while the crimps of the adjacent fibers are misaligned, which allows thefiber bundle to be opened.

[Step (a₄)]

As illustrated in FIG. 1, the step (a₄) is performed by the air feeder108, which is disposed downstream from the second nip rolls 106 andblows air in a direction intersecting with the machine direction of thebelt-shaped fiber bundle F′1.

In an embodiment of the method of producing an opened fiber bundle andthe apparatus which opens a fiber bundle according to the presentdisclosure, the step (a₄) is performed after the step (a₃) completes. Inanother embodiment of the method of producing an opened fiber bundle andthe apparatus which opens a fiber bundle according to the presentdisclosure, the step (a₄) at least partially overlaps with the step(a₃). For example, the step (a₄) is performed during the step (a₃).

In FIG. 1, the air feeder 108 is disposed between the second nip rolls106 and the third nip rolls 114, and blows air in a directionintersecting with the machine direction of the first belt-shaped fiberbundle F′1, through its nozzle. The blown air allows the firstbelt-shaped fiber bundle F′1 to be further widened. Depending on theconditions for blowing air, the fibers located in the middle of thewidth can be dispersed on the edges of the width, and/or the firstbelt-shaped fiber bundle F′1 can be further opened.

In another embodiment of the method of producing an opened fiber bundleand the apparatus which opens a fiber bundle according to the presentdisclosure, the air is blown in the direction of the thickness of thefirst belt-shaped fiber bundle. In still another embodiment of themethod of producing an opened fiber bundle and the apparatus which opensa fiber bundle according to the present disclosure, air is blown in thedirection inclined upstream in the machine direction of the fiberbundle.

In another embodiment of the method of producing an opened fiber bundleand the apparatus which opens a fiber bundle according to the presentdisclosure, air is blown up onto the belt-shaped fiber bundle throughthe air outlet, which is disposed below, preferably vertically below thebelt-shaped fiber bundle. Blowing up air from below the belt-shapedfiber bundle allows the belt-shaped fiber bundle to be floated, and thusthe belt-shaped fiber bundle can be further widened.

In another embodiment of the method of producing an opened fiber bundleand the apparatus which opens a fiber bundle according to the presentdisclosure, the air is blown up onto the belt-shaped fiber bundlethrough the air outlet which is disposed below the belt-shaped fiberbundle, and a float control plate is disposed above the air outlet sothat the belt-shaped fiber bundle is sandwiched between the plate andthe air outlet to prevent the belt-shaped fiber bundle from floating.

In another embodiment of the method of producing an opened fiber bundleand the apparatus which opens a fiber bundle according to the presentdisclosure, an air feeder is disposed downstream from the third niprolls.

[Other Steps]

An embodiment of the method of producing an opened fiber bundleaccording to the present disclosure further includes a step of applyingdust adsorbent oil to a fiber bundle. The step may be performed afterthe step (a₂) completes or may at least partially overlap with the step(a₂).

An embodiment of the apparatus which opens a fiber bundle according tothe present disclosure includes an oil applicator.

In FIG. 1, the oil applicator 110 and a dust adsorbent oil bath 112 aredisposed between the second nip rolls 106 and the third nip rolls 114.Dust adsorbent oil is transferred from the dust adsorbent oil bath 112to the oil applicator 110, i.e., oil transfer roll, and then the dustadsorbent oil is transferred from the oil transfer roll to the firstbelt-shaped fiber bundle F′1. The dust adsorbent oil acts to enhanceadsorption of dust, dirt, and the like and includes, for example, liquidparaffin and surfactant as major components.

In another embodiment of the method of producing an opened fiber bundleand the apparatus which opens a fiber bundle according to the presentdisclosure, the oil applicator is disposed at a location other thanbetween the second nip rolls and the third nip rolls such as, a locationupstream from the second nip rolls or a location downstream from thethird nip rolls.

Still another embodiment of the method of producing an opened fiberbundle and the apparatus which opens a fiber bundle according to thepresent disclosure does not include the step of applying dust adsorbentoil and/or the oil applicator.

FIG. 2 illustrates a method of producing an opened fiber bundle and anapparatus which opens a fiber bundle according to another embodiment ofthe present disclosure. An apparatus which opens a fiber bundle 101illustrated in FIG. 2 includes, between first nip rolls 102 and secondnip rolls 106, an opening facilitator 115, which includes an edge (notillustrated) extending orthogonal to the machine direction, an upstreamportion (not illustrated) adjacently located upstream from the edge, anda downstream portion (not illustrated) adjacently located downstreamfrom the edge, and the apparatus 101 illustrated in FIG. 2 has the sameconfiguration as the apparatus which opens a fiber bundle 101illustrated in FIG. 1, except that the apparatus illustrated in FIG. 2conveys a fiber bundle F1 with the fiber bundle pushed onto the upstreamportion and the edge of the opening facilitator 115.

FIG. 3 is an enlarged environmental perspective view of the openingfacilitator 115 illustrated in FIG. 2. The opening facilitator 115illustrated in FIG. 3 includes an edge 116 extending in the crossmachine direction (CD) orthogonal to the machine direction MD, anupstream portion 117 adjacently located upstream from the edge 116, anda downstream portion 118 adjacently located downstream from the edge.

The fiber bundle F1 is conveyed with the fiber bundle F1 pushed onto theupstream portion 117 and the edge 116 of the opening facilitator 115.Conveying of the fiber bundle F1 with the fiber bundle F1 pushed ontothe upstream portion 117 and the edge 116 of the opening facilitator 115allows the fiber bundle F1 to be widen in the width direction of thefiber bundle F1, thereby causing the machine direction of the fiberswhich constitute the fiber bundle F1 to be strained in the widthdirection (in the width direction of the fiber bundle).

FIG. 4 is an enlarged environmental side view of the opening facilitator115 illustrated in FIG. 2. The fiber bundle F1 changes its conveyingdirection (machine direction) to a direction toward a first surface 119a. The first surface 119 a is a surface of the fiber bundle F1, thesurface contacting with the opening facilitator 115. As a result, thefibers of the fiber bundle F1 which the fibers are located around asecond surface 119 b opposite to the first surface 119 a travel, at theedge 116, over a longer distance compared with the fibers around thefirst surface 119 a. Thus, the fibers which constitute the fiber bundleF1 are strained in the thickness direction (in the thickness directionof the fiber bundle).

As described above, the fibers of the fiber bundle F1 are strained inthe directions of both of the thickness and the width on the openingfacilitator 115. Thus the fibers are more readily opened, compared withthe method described in PTL 1, the method straining fibers only in thedirection of the thickness.

In the method of producing an opened fiber bundle and/or the apparatuswhich opens a fiber bundle according to the present disclosure, thefiber bundle changes its conveying direction, at the edge of the openingfacilitator, to a direction toward the first surface preferably by anangle of 30 to 150°, and more preferably by an angle of 60 to 120°. Whenthe angle is less than 30°, the edge has a high curvature, and thus thefibers tend to break, and a failure tends to occur due to entanglementin a roll or the like. On the other hand, when the angle is more than150°, the ability to facilitate opening tends to be reduced.

In the method of producing an opened fiber bundle and/or the apparatuswhich opens a fiber bundle according to the present disclosure, the edgeof the opening facilitator has preferably an angle of 30 to 150° andmore preferably an angle of 60 to 120°, in order to correspond to thechange in the conveying direction of the fiber bundle.

Because the opening facilitator 115 includes the upstream portion 117adjacently located upstream from the edge 116, a large localized force,specifically a large localized force from the edge 116 is less likely tobe applied to the fibers which constitute the fiber bundle F1, and thusthe fibers are less likely to break.

The opening facilitator 115 illustrated in FIG. 3 and FIG. 4 includesthe downstream portion 118 adjacently located downstream from the edge116. After the fiber bundle F1 runs through the edge 116, the fiberbundle F1 is conveyed along the downstream portion 118. Because thefiber bundle F1 is conveyed along the downstream portion 118, a largelocalized force, specifically a large localized force from the edge 116is less likely to be applied to the fibers which constitute the fiberbundle F1, and thus the fibers are less likely to break.

In another embodiment of the method of producing an opened fiber bundleand/or the apparatus which opens a fiber bundle according to the presentdisclosure, after the fiber bundle runs through the edge, the fiberbundle is conveyed with the fiber bundle pushed onto the downstreamportion 118. Conveying of the fiber bundle with the fiber bundle pushedallows the fiber bundle to be more readily opened.

Although the edge 116 of the opening facilitator 115 illustrated in FIG.3 and FIG. 4 is not rounded, in another embodiment of the method ofproducing an opened fiber bundle and the apparatus which opens a fiberbundle according to the present disclosure, the opening facilitatorincludes a rounded edge.

In still another embodiment of the method of producing an opened fiberbundle and the apparatus which opens a fiber bundle according to thepresent disclosure, the fiber bundle does not run along the downstreamportion. In other words, the fiber bundle is conveyed in a directionother than along the downstream portion.

FIG. 5 is a side view of an opening facilitator used in a method ofproducing an opened fiber bundle and an apparatus which opens a fiberbundle according to another embodiment of the present disclosure, andcorresponds to the enlarged environmental side view of the openingfacilitator 115 illustrated in FIG. 2. On the opening facilitator 115illustrated in FIG. 5, the fiber bundle F1 is conveyed in a directionother than along the downstream portion 118′ adjacently locateddownstream from the edge 116.

The upstream portion 117 and the downstream portion 118 of the openingfacilitator 115 illustrated in FIG. 3 to FIG. 5 are both a planesurface. In another embodiment of the method of producing an openedfiber bundle and the apparatus which opens a fiber bundle according tothe present disclosure, the upstream portion and/or the downstreamportion are selected from the group consisting of a plane surface and aconvex surface.

The opening facilitator 115 illustrated in FIG. 3 to FIG. 5 includes twoplane surfaces (the upstream portion 117 and the downstream portion 118)which meet at the edge 116 in a cross direction (CD) and a curvedsurface 115 a, which is disposed between the plane surfaces and has anapproximately fan-shaped machine direction section.

In some other embodiments of the method of producing an opened fiberbundle and the apparatus which opens a fiber bundle according to thepresent disclosure, the opening facilitator has a polygonal crossdirection section such as, a trigonal, tetragonal, pentagonal, orhexagonal cross direction section.

Although the opening facilitator 115 illustrated in FIG. 3 to FIG. 5 isstatic, in another embodiment of the method of producing an opened fiberbundle and the apparatus which opens a fiber bundle according to thepresent disclosure, the opening facilitator may be dislocated based onthe opening state, while monitoring the opening of the fiber bundle.

FIG. 6 illustrates a method of producing an opened fiber bundle and anapparatus which opens a fiber bundle according to still anotherembodiment of the present disclosure. An apparatus which opens a fiberbundle 101 illustrated in FIG. 6 includes, downstream from the secondnip rolls 106, more specifically between the second nip rolls 106 andthe air feeder 108, a widening member 201, which widens the belt-shapedfiber bundle F′1 in the width direction, and the apparatus illustratedin FIG. 6 has the same configuration as the apparatus which opens afiber bundle 101 illustrated in FIG. 1, except that the apparatusillustrated in FIG. 6 contacts the belt-shaped fiber bundle with thewidening member.

FIG. 7 is a perspective view of the widening member 201 as illustratedin FIG. 6 which the member 201 is widening a belt-shaped fiber bundleF′1 in the width direction W. The widening member 201 illustrated inFIG. 7 includes a curved portion 202, which is downwardly curved towardthe thickness direction T of the belt-shaped fiber bundle F′1, and thebelt-shaped fiber bundle F′1 is conveyed while contacting with thecurved portion 202. As a result, the fibers contacted with the curvedportion 202 are widened in the width direction W, thereby uniforming thebasis weight of the belt-shaped fiber bundle F′1.

Especially, the basis weight of the fibers of the belt-shaped fiberbundle F′1 conveyed from the second nip rolls 102 tends to be largercloser to the center of the width. Thus widening of the fibers in thewidth direction allows the basis weight of the belt-shaped fiber bundleF′1 to be uniformed.

In addition, use of the widening member allows shortening of theoperation cycle of the apparatus which opens a fiber bundle.

Although the widening member 201 is disposed between the second niprolls 106 and the air feeder 108 in FIG. 6, in another embodiment of themethod of producing an opened fiber bundle and the apparatus which opensa fiber bundle according to the present disclosure, the widening memberis disposed downstream from the second nip rolls, for example,downstream from the air feeder.

FIG. 8 illustrates a method of producing an opened fiber bundle and anapparatus which opens a fiber bundle according to still anotherembodiment of the present disclosure. The apparatus which opens a fiberbundle 101 illustrated in FIG. 8 includes, downstream from the secondnip rolls 106, more specifically between the second nip rolls 106 andthe air feeder 108, the widening member 201, which contacts with thebelt-shaped fiber bundle F′1 and widens the belt-shaped fiber bundle F′1in the width direction W, and the apparatus illustrated in FIG. 8 hasthe same configuration as the apparatus which opens a fiber bundle 101illustrated in FIG. 1, except that the apparatus illustrated in FIG. 8contacts the belt-shaped fiber bundle F′1 with the widening member 201.

<<Method of Producing Cleaning Member and System which Produces CleaningMember>>

The method of producing a cleaning member according to the presentdisclosure includes the steps of:

(A) continuously producing an opened fiber bundle (hereinafter referredto as “step (A)”),

(B) stacking the opened fiber bundle with one or more other materials toform a multilayer web and fixing the respective materials of themultilayer web to each other (hereinafter referred to as “step (B)”),and

(C) cutting the fixed multilayer web into individual cleaning members(hereinafter referred to as “step (C)).

The system which produces a cleaning member according to the presentdisclosure includes:

an apparatus which opens a fiber bundle,

one or more apparatuses which stack the opened fiber bundle with one ormore other materials to form a multilayer web and fix the respectivematerials of the multilayer web to each other, and

one or more apparatuses which cut the fixed multilayer web intoindividual cleaning members.

By way of example, the cleaning member illustrated in FIGS. 10 to 12will be described and then the present disclosure will be describedalong with the method of producing a cleaning member and with referenceto FIG. 9.

FIG. 9 is a schematic view of an apparatus which opens a fiber bundleand a system which produces a cleaning member according to an embodimentof the present disclosure. The method of producing an opened fiberbundle and the method of producing a cleaning member according to thepresent disclosure can be carried out using the apparatus which opens afiber bundle and the system which produces a cleaning member illustratedin FIG. 9.

FIG. 10 to FIG. 12 illustrate a cleaning member 1 produced using thesystem which produces a cleaning member 100 illustrated in FIG. 9.

FIG. 10 is an overall perspective view of a cleaning member 1 and ahandle 15, and FIG. 11 is a cross sectional view taken along the lineXI-XI in FIG. 10. And FIG. 12 is a plan view of the cleaning member 1 inFIG. 10.

The cleaning member 1 illustrated in FIG. 10 to FIG. 12 includes a brushpart 2 including a first fibrous member 3, a second fibrous member 4, athird fibrous member 5, a fourth fibrous member 6, and a sheet withslits 7 disposed under the fourth fibrous member 6; a substrate sheet 12stacked on the raised portion 2; and a holding sheet 13 stacked on thesubstrate sheet 12. And a receiving part 14 is disposed between thesubstrate sheet 12 and the holding sheet 13, into which an insert part16 of the handle 15 is inserted.

The upper portion in FIG. 11 is held by the handle, while the lowerportion is used for cleaning.

The cleaning member 1 illustrated in FIGS. 10 to 12 includes tworeceiving parts 14 into which the two-branched insert part 16 of thehandle 15 can be inserted. The insert part of the handle, however, mayinclude three or more branches or include no branches. The number of thereceiving parts of the cleaning member varies depending on the number ofthe branches of the insert part of the handle.

As illustrated in FIG. 10, the brush part 2 includes a four-layeredfibrous unit which includes the first fibrous member 3, the secondfibrous member 4 disposed under the first fibrous member 3, the thirdfibrous member 5 disposed under the second fibrous member 4, and thefourth fibrous member 6 disposed under the third fibrous member 5; andthe sheet with slits 7, which is disposed under the fourth fibrousmember 6 of the four-layered fibrous unit. The fibrous unit of the brushpart 2 is not limited to the four-layered structure and may include one,two, three, or five or more layers. In another embodiment, the brushpart 2 does not include the sheet with slits 7.

Dust adsorbent oil which enhances adsorption of dust, dirt, and the likeand which includes, for example, liquid paraffin as a major component isapplied to the first, second, third, and fourth fibrous members 3, 4, 5,and 6 of the brush part 2.

The first, second, third, and fourth fibrous member 3, 4, 5, and 6 ofthe brush part 2 may be formed by cutting an opened fiber bundle suchas, an opened tow.

As used herein, “tow” means a bundle of a multiplicity of filaments, asdescribed in JIS L 0204-3: 1998, 3.1.24.

The fiber bundle as described above includes, for example, a fiberbundle which consists of thermoplastic fibers and a fiber bundle whichincludes thermoplastic fibers.

The fiber materials which constitute the fiber bundle as described aboveinclude, for example, polyethylene, polypropylene, polyethyleneterephthalate, nylon, rayon, and the like.

The fibers which constitute the fiber bundle as described above include,for example, monofibers and bicomponent fibers such as, sheath-corebicomponent fibers and side-by-side bicomponent fibers.

The bicomponent fibers as described above are preferably sheath-corebicomponent fibers, and more preferably sheath-core bicomponent fiberswhich have a core melting point higher than a sheath melting point, dueto its thermal bondability.

The sheath-core bicomponent fibers as described above are morepreferably sheath-core bicomponent fibers which have a core ofpolypropylene or polyethylene terephthalate and a sheath ofpolyethylene, and still more preferably sheath-core bicomponent fiberswhich have a core of polyethylene terephthalate and a sheath ofpolyethylene.

The fibers which constitute the fiber bundle have preferably a finenessof 1 to 50 dtex, and more preferably a fineness of 2 to 10 dtex. Thefiber bundle may include a plurality of different fibers which have asame fineness or may include a single type or a plurality of differentfibers which have a different fineness.

The fiber bundle as described above may be a bundle of slit fibers,which are formed by slitting and drawing a film, split fibers, which areformed by splitting an elongated film into network segments, or thelike.

In an embodiment of the method of producing a cleaning member and thesystem which produces a cleaning member according to the presentdisclosure, the fiber bundle includes or consists of crimped fibers.Because the fiber bundle includes crimped fibers, the fiber bundle canbe bulked, and the crimped areas in the brush part formed of the fiberbundle can more easily adsorb dust and dirt.

In another embodiment of the method of producing a cleaning member andthe system which produces a cleaning member according to the presentdisclosure, the fiber bundle does not include crimped fibers.

As described below, the sheet with slits 7 is formed of a nonwovenfabric which consists of or includes thermoplastic fibers (thermallybondable fibers), as with the substrate sheet 12 and the holding sheet13. And the sheet with slits 7 is formed in a rectangular shape havingapproximately the same width and length as the substrate sheet 12. Thesheet with slits 7 is provided with jagged slits (not illustrated) atpredetermined intervals over the entire length of the sheet with slits7. The slits allow jagged reed-shaped parts (not illustrated) to beformed on both width edges of the cleaning member.

As illustrated in FIG. 10 to FIG. 12, the substrate sheet 12 and theholding sheet 13 are stacked, in this order, on the first fibrous member3 of the brush part 2, and the receiving part 14 into which the insertpart 16 of the handle 15 is inserted is disposed between the substratesheet 12 and the holding sheet 13.

As illustrated in FIG. 12, the substrate sheet 12 and the holding sheet13 have the same length in the width direction of the cleaning member,but have a different length in the longitudinal direction of thecleaning member. In other words, the substrate sheet 12 has a longerlength in the longitudinal direction of the cleaning member. The holdingsheet 13 is stacked on the substrate sheet 12 so that the eachlongitudinal end of the substrate sheet 12 protrudes outward from thecorresponding longitudinal end of the holding sheet 13 by apredetermined distance.

For the cleaning member 1 illustrated in FIG. 10 to FIG. 12, “thelongitudinal direction of the cleaning member” (the vertical directionin FIG. 12) means a direction of insertion of the handle 15, while “thewidth direction of the cleaning member” (the horizontal direction inFIG. 11 and FIG. 12) means a direction orthogonal to the longitudinaldirection of the cleaning member.

The substrate sheet 12 and the holding sheet 13 are formed of a nonwovenfabric which consists of or includes thermoplastic fibers (thermallybondable fibers). The thermoplastic fibers include, for example,polyethylene fibers, polypropylene fibers, polyethylene terephthalatefibers, bicomponent fibers of polyethylene and polyethyleneterephthalate such as, sheath-core bicomponent fibers which have a coreof polyethylene terephthalate and a sheath of polyethylene andbicomponent fibers of polyethylene and polypropylene, and the like. Thenonwoven fabric includes a thermal-bonded nonwoven fabric, a spun-bondednonwoven fabric, a spun-laced nonwoven fabric, and the like.

In another embodiment, the substrate sheet and the holding sheet areformed of a thermoplastic resin film such as, a polyethylene film and apolypropylene film. In still another embodiment, the substrate sheet andthe holding sheet are formed of a laminate sheet of a nonwoven fabricand a resin film.

The substrate sheet 12 and the holding sheet 13 are melt bonded to theentire layers of the brush part 2 (the first, second, third, and fourthfibrous members 3, 4, 5, and 6, and the sheet with slits 7) by the firstmelt bonding apparatus as described below, which is numbered 158 in FIG.9, and then the first melt bonded part 8 which extends in thelongitudinal direction of the cleaning member is formed at the center ofthe width of the cleaning member, as illustrated in FIG. 10 to FIG. 12.

Additionally, the substrate sheet 12 and the holding sheet 13 are meltbonded to one of the layers of the brush part 2 (the first fibrousmember 3), on the opposing sides of the first melt bonded part 8, by thesecond melt bonding apparatus as described below, which is numbered 134in FIG. 9, and then two second melt bonded parts 11 are formed in thelongitudinal direction. Each of the two second melt bonded parts 11 isformed as a dotted line. Melt bonding of the first fibrous member 3 tothe substrate sheet 12 and the holding sheet 13 allows the first fibrousmember 3 to be moved with the sheets 12 and 13, thereby facilitatingspreading of the brush part 2 in use and thus improving cleaningefficiency.

The substrate sheet 12 and the holding sheet 13 are melt bonded to theentire layers of the brush part 2 (the first, second, third, and fourthfibrous members 3, 4, 5, and 6 and the sheet with slits 7) by the firstmelt bonded part 8, and the substrate sheet 12 and the holding sheet 13are also melt bonded to the first fibrous member 3 of the brush part 2by the two second melt bonded parts 11. This allows a pair of thereceiving parts 14 to be formed between the substrate sheets 12 and theholding sheet 13, the receiving parts being defined by the first meltbonded part 8 and one of the two second melt bonded parts 11, extendingin the longitudinal direction of the substrate sheet 12 and the holdingsheet 13, and being a tube open at opposing longitudinal sides. Thus,the insert part 16 of the handle 15 can be inserted into the receivingparts 14.

The substrate sheet 12 and the holding sheet 13 are melt bonded to thefirst fibrous member 3 of the brush part 2 along the longitudinalcenterline of the cleaning member by the second melt bonding apparatusas described below, which is numbered 134 in FIG. 9, and thus a pair ofmelt bonded lines 18 are formed at a predetermined width distance fromeach other. Between the pair of the melt bonded lines 18, the first meltbonded part 8 is formed. The pair of the melt bonded lines 18 are markswhich are used to control the position of the first melt bonded part 8during manufacturing. Good and flawed products are distinguished bydetermining, using a sensor or the like, whether the first melt bondedpart 8 is located between the melt bonded lines 18.

Each of the two second melt bonded parts 11 is disposed as a dotted linein the longitudinal direction. A circular arc projection 16 a of therespective insert part 16 of the handle 15 is locked into a non-bondedarea in the second melt bonded parts 11 to prevent removal of therespective insert part 16 of the handle 15 from the respective receivingpart 14.

As illustrated in FIG. 10, the substrate sheet 12 and the holding sheet13 are provided with jagged slits 20 a. The slits 20 a are disposed atpredetermined intervals on the opposing width edges of the cleaningmember (outwardly of the two second melt bonded parts 11) and in thelongitudinal direction of the cleaning member. A plurality ofreed-shaped parts 20 with jagged edges are defined in the substratesheet 12 and the holding sheet 13 by the slits 20 a.

In another embodiment, the substrate sheet 12 and the holding sheet 13include no jagged slits 20 a, and thus the cleaning member includes noreed-shaped parts 20.

The handle 15 is formed of plastic or the like, and, as illustrated inFIG. 10, includes a pair of rectangular insert parts 16 disposedparallel to each other; a pair of circular arc projections 16 aprotruding from the lateral surface of the opposing longitudinal edgeportions of the respective insert parts 16, and a holder 17 integrallydisposed at one end of the insert parts 16.

The respective insert parts 16 of the handle 15 are inserted into therespective receiving parts 14 of the cleaning member 1, and projections16 a are locked into a non-bonded area in the second melt bonded parts11 to attach the cleaning member 1 to the handle 15.

A user holds the holder 17 of the handle 15, contacts the brush part 2with a surface to be cleaned, and moves the cleaning member in a desireddirection so that the brush part 2 adsorbs the dust, dirt, and the likeon the surface, for cleaning the surface.

The cleaning member illustrated in FIG. 10 to FIG. 12 is an example ofthe cleaning members which can be produced using the method of producingan opened fiber bundle, the method of producing a cleaning member, theapparatus which opens a fiber bundle, and/or the system which produces acleaning member according to the present disclosure. The method ofproducing a cleaning member, and the system which produces a cleaningmember according to the present disclosure can be used to produce acleaning member as described in, for example, Japanese Unexamined PatentPublication No. 2000-296083, 2003-265390, 2003-268663, 2004-223692,2005-046645, 2005-095665, 2005-111284, 2005-137929, 2005-137930,2005-137931, 2005-144198, 2005-169148, 2005-199077, 2005-230573,2005-237975, 2006-015164, 2006-034990, 2006-141483, 2007-135774,2007-209460, 2007-209461, 2007-029136, 2007-111297, 2007-135666,2007-136156, 2007-159612, 2007-236690, 2008-006260, 2008-119171, and2007-029135, the entire disclosure of which is incorporated herein byreference.

In addition, the method of producing a cleaning member and the systemwhich produces a cleaning member according to the present disclosure canbe used to produce a cleaning member as described in, for example, U.S.Pat. No. 6,554,937B, US2002/148061A, US2003/0000934A, US2004/0149095A,US2005/0005381A, US2005/039285A, US2005/097695A, US2005/097696A,US2005/132521A, US2005/177967A, US2005/188490A, US2005/193513A,US2005/193514A, US2005/198760A, US2006/016035A, US2006/016036A,US2006/101601A, US2009/165230A and US2009/172904A, as well asUS2009/049633A, US2009/255078A and US2010/154156A, the entire disclosureof which is incorporated herein by reference.

[Step (A)]

The description of the step (A) is omitted. For the details, see “Methodof Producing Opened Fiber Bundle and Apparatus which opens Fiber Bundle”described above.

[Step (B)]

In the step (B), the opened fiber bundle is stacked with one or moreother materials to form a multilayer web, and the respective materialsof the multilayer web are fixed to each other. The one or more othermaterials which constitute the multilayer web include one or more openedfiber bundles, nonwoven fabrics, and the like. The method of fixing asdescribed above includes use of adhesive such as, hot-melt adhesive,sealing such as, heat sealing and ultrasonic sealing, and the like.

Although the method of producing a cleaning member and the system whichproduces a cleaning member according to the present disclosure is notintended to include a multilayer web of a particular structure, one ofthe embodiments will be described with reference to FIG. 9.

In FIG. 9, the first belt-shaped fiber bundle F′1 runs through the thirdnip rolls 114 and then goes to a merging point 132.

On the other hand, a belt-shaped nonwoven fabric 121, which is to formthe substrate sheet 12, is continuously wound off from a nonwoven fabricroll 120. The belt-shaped nonwoven fabric 121 is intermittently conveyedby running the belt-shaped nonwoven fabric 121 through a dancer roller124, which includes a plurality of rolls arranged in upper and lowerrows, the rolls in the lower row oscillating up and down. As usedherein, “intermittently conveying” refers to repeating a cycle ofconveying materials a certain distance (for example, a lengthcorresponding to the width length of the cleaning member) and thenhalting conveying for a certain period. Intermittent conveying ofmaterials allows time to be gained for melt bonding the components ofthe multilayer web as described below.

Similarly, a belt-shaped nonwoven fabric 123, which is to form theholding sheet 13, is continuously wound off from a nonwoven fabric roll122. The belt-shaped nonwoven fabric 123 is intermittently conveyed byrunning the belt-shaped nonwoven fabric 123 through a dancer roller 126,which includes a plurality of rolls arranged in upper and lower rows,the rolls in the lower row oscillating up and down.

The belt-shaped nonwoven fabric 123 is stacked onto the belt-shapednonwoven fabric 121 at merging point 128 to form a multilayer web S1 ofthe belt-shaped nonwoven fabric 121 and the belt-shaped nonwoven fabric123. The multilayer web S1 runs through a gather cutter 130, whichincludes serrated blades (not illustrated) formed at spaced apartlocations on its circumferential surface, to make slits into themultilayer web S1. The slits in the multilayer web S1 correspond to theslits 20 a in the substrate sheet 12 and the holding sheet 13illustrated in FIG. 10.

Then the first belt-shaped fiber bundle F′1 is stacked onto themultilayer sheet S1 at the merging point 132 to form a multilayer web S2of the first belt-shaped fiber bundle F′1 and the multilayer sheet S1.

The zone between the third nip rolls 114 and the merging point 132 isconfigured to convey the first belt-shaped fiber bundle F′1 with thefirst belt-shaped fiber bundle F′1 flexed to some extent. The flexingbrings the similar result of disposing a dancer roller between the thirdnip rolls 114 and the merging point 132.

The substrate sheet 12, the holding sheet 13, and the first fiber bundleF1, which constitute the multilayer web S2, are melt bonded by a secondmelt bonding apparatus 134 to form the two second melt bonded parts 11(see FIG. 11). For the method of producing a cleaning member and thesystem which produces a cleaning member according to the presentdisclosure, the second melt bonding apparatus includes, for example, aheat-sealing apparatus, an ultrasonic sealing apparatus, and the like.

Next, in the same manner for the first fiber bundle F1, an opened secondfiber bundle F2 (a second belt-shaped fiber bundle F′2) is stacked ontothe multilayer web S2 at a merging point 136, and a third fiber bundleF3 (a third belt-shaped fiber bundle F′3) is stacked onto the resultingweb at a merging point 138. Then a fourth fiber bundle F4 (a fourthbelt-shaped fiber bundle F′4) is stacked onto the resulting web at amerging point 140 to form a multilayer web S3.

Next, a belt-shaped nonwoven fabric 151, which is to form the sheet withslits 7, is continuously wound off from a nonwoven fabric roll 150. Thebelt-shaped nonwoven fabric 151 is intermittently conveyed by runningthe belt-shaped nonwoven fabric 151 through a dancer roller 152, andthen runs through a gather roll 154. The gather roll 154 includesserrated blades (not illustrated) continuously formed on itscircumferential surface, thereby making jagged slits (not illustrated)into the belt-shaped nonwoven fabric 151 running through the gather roll154.

The sheet with slits 7 formed of the belt-shaped nonwoven fabric 151 isstacked onto the multilayer web S3 at a merging point 156 to form amultilayer web S4 of the sheet with slits 7 and the multilayer web S3.

Then the multilayer web S4 is melt bonded in the thickness directionusing a first melt bonding apparatus 158 to form the first melt bondedpart 8 (see FIG. 12 and the like) in the multilayer web S4. For themethod of producing a cleaning member and the system which produces acleaning member according to the present disclosure, the first meltbonding apparatus includes, for example, a heat-bonding apparatus, anultrasonic sealing apparatus, and the like.

[Step (C)]

As the method of producing a cleaning member and the system whichproduces a cleaning member according to the present disclosure is notintended to include a multilayer web of a particular structure, the step(C) is not particularly limited, so long as the step can cut the fixedmultilayer web into individual cleaning members.

After the multilayer web S4 runs through the first melt bondingapparatus 158, the web S4 is cut by a cutter unit 160 to produce thecleaning member 1.

Although the system which produces a cleaning member 100 illustrated inFIG. 9 includes the gather roll 154, another embodiment of the method ofproducing a cleaning member and the system which produces a cleaningmember according to the present disclosure does not include the gatherroll, and the resulting cleaning members include a nonwoven fabricsheet, instead of the sheet with slits.

Still another embodiment of the method of producing a cleaning memberand the system which produces a cleaning member according to the presentdisclosure does not include the gather roll and the step performedupstream from the roll, and the resulting cleaning members include afibrous member formed as a cleaning surface.

Although the system which produces a cleaning member 100 illustrated inFIG. 9 forms a receiving part below the surface of the cleaning member,in another embodiment of the method of producing a cleaning member andthe system which produces a cleaning member according to the presentdisclosure, the order of stacking the substrate sheet, the holding sheetand the fibrous member is changed to dispose a receiving part betweenany adjacent fibrous members. This allows the both surfaces of thecleaning member to be used for cleaning.

In another embodiment of the method of producing a cleaning member andthe system which produces a cleaning member according to the presentdisclosure, in order to facilitate insertion of the insert part into thereceiving part, the substrate sheet and the holding sheet are preferablyconfigured to have a larger longitudinal dimension compared with thefibrous members. In still another embodiment of the method of producinga cleaning member and the system which produces a cleaning memberaccording to the present disclosure, the sheet with slits is notstacked. In still another embodiment, the sheet with slits 7 is stackedonto the both surfaces of the cleaning member 1.

The present disclosure relates to the following J1 to J14:

[J1]

A method of continuously producing an opened fiber bundle for a cleaningmember, comprising the steps of:

(a₁) providing (i) first nip rolls, (ii) second nip rolls, which aredisposed downstream from the first nip rolls and have a fasterperipheral velocity compared with the first nip rolls, (iii) third niprolls, which are disposed downstream from the second nip rolls and havea slower peripheral velocity compared with the second nip rolls, and(iv) an air feeder which is disposed downstream from the second niprolls;

(a₂) conveying the fiber bundle using the first nip rolls and the secondnip rolls to apply a tensile force to the fiber bundle;

(a₃) conveying the fiber bundle using the second nip rolls and the thirdnip rolls to relax the fiber bundle, thereby forming a belt-shaped fiberbundle; and

(a₄) blowing air from the air feeder in a direction intersecting withorthogonal to the conveying direction of the belt-shaped fiber bundle.

[J2]

The method according to J1, wherein an opening facilitator whichcomprises an edge extending orthogonal to the machine direction, anupstream portion adjacently located upstream from the edge, and adownstream portion adjacently located downstream from the edge isdisposed between the first nip rolls and the second nip rolls, and thefiber bundle is conveyed with the fiber bundle pushed onto the upstreamportion and the edge of the opening facilitator.

[J3]

The method according to J2, wherein after the fiber bundle runs throughthe edge, the fiber bundle is conveyed along the downstream portion ofthe opening facilitator.

[J4]

The method according to J2 or J3, wherein the opening facilitator isstatic.

[J5]

The method according to any one of J1 to J4, wherein a widening memberwhich widens the belt-shaped fiber bundle in the width direction, isdisposed downstream from the second nip rolls, and the belt-shaped fiberbundle is contacted with the widening member.

[J6]

The method according to J5, wherein the widening member comprises acurved portion which is downwardly curved toward the thickness directionof the belt-shaped fiber bundle, and the belt-shaped fiber bundle isconveyed while contacting with the curved portion.

[J7]

A method of producing a cleaning member, comprising the steps of:

(A) continuously producing an opened fiber bundle using the methodaccording to any one of J1 to J6;

(B) stacking the opened fiber bundle with one or more other materials toform a multilayer web and fixing the respective materials of themultilayer web to each other; and

(C) cutting the fixed multilayer web into individual cleaning members.

[J8]

An apparatus which opens a fiber bundle for a cleaning member,comprising:

first nip rolls

second nip rolls, which are disposed downstream from the first niprolls, have a faster peripheral velocity compared with the first niprolls, and, together with the first nip rolls, convey the fiber bundleto apply a tensile force to the fiber bundle,

third nip rolls, which are disposed downstream from the second niprolls, have a slower peripheral velocity compared with the second niprolls, and, together with the second nip rolls, convey the fiber bundleto relax the fiber bundle, thereby forming a belt-shaped fiber bundle,and

an air feeder which is disposed downstream from the second nip rolls andblows air in a direction intersecting with the conveying direction ofthe belt-shaped fiber bundle.

[J9]

The apparatus according to J8, the apparatus further comprising anopening facilitator which comprises an edge extending orthogonal to themachine direction, an upstream portion adjacently located upstream fromthe edge, and a downstream portion adjacently located downstream fromthe edge and is disposed between the first nip rolls and the second niprolls so that the fiber bundle is conveyed with the fiber bundle pushedonto the upstream portion and the edge.

[J10]

The apparatus according to J9, wherein the opening facilitator isdisposed so that the fiber bundle is conveyed along the downstreamportion.

[J11]

The apparatus according to J9 or J10, wherein the opening facilitator isstatic.

[J12]

The apparatus according to any one of J9 to J11, the apparatuscomprising, downstream from the second nip rolls, a widening memberwhich widens the belt-shaped fiber bundle in the width direction tocontact with the belt-shaped fiber bundle.

[J13]

The apparatus according to J12, wherein the widening member comprises acurved portion which is downwardly curved toward the thickness directionof the belt-shaped fiber bundle to convey the belt-shaped fiber bundlewhile contacting with the curved portion.

[J14]

A system which produces a cleaning member, comprising:

the apparatus which opens a fiber bundle according to any one of J8 toJ13;

one or more apparatuses which stack the opened fiber bundle with one ormore other materials to form a multilayer web and fix the respectivematerials of the multilayer web to each other; and

one or more apparatuses which cut the fixed multilayer web intoindividual cleaning members.

The present application claims the benefit of the following patentapplications, and the entire disclosure of which is incorporated hereinby reference:

(1) JP Patent Application No. 2012-289181 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(2) JP Patent Application No. 2012-289182 filed on Dec. 29, 2012,

(3) JP Patent Application No. 2012-289174 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(4) JP Patent Application No. 2012-289189 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(5) JP Patent Application No. 2012-289175 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(6) JP Patent Application No. 2012-289188 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(7) JP Patent Application No. 2012-289179 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(8) JP Patent Application No. 2012-289177 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(9) JP Patent Application No. 2012-289184 filed on Dec. 29, 2012, and USpatent application claiming priority thereof,

(10) JP Patent Application No. 2012-289178 filed on Dec. 29, 2012, andUS patent application claiming priority thereof,

(11) JP Patent Application No. 2012-289176 filed on Dec. 29, 2012, andUS patent application claiming priority thereof,

(12) JP Patent Application No. 2013-002855 filed on Jan. 10, 2013, andUS patent application claiming priority thereof, as well as

(13) JP Patent Application No. 2013-002857 filed on Jan. 10, 2013, andUS patent application claiming priority thereof.

REFERENCE SIGNS LIST

-   1 cleaning member-   2 brush part-   3 first fibrous member-   4 second fibrous member-   5 third fibrous member-   6 fourth fibrous member-   7 sheet with slits-   8 first melt bonded part-   11 second melt bonded part-   12 substrate sheet-   13 holding sheet-   14 receiving part-   15 handle-   16 insert part-   16 a projection-   17 holder-   18 melt bonded line-   20 reed-shaped part-   20 a slit-   100 system which produces cleaning member-   101 apparatus which opens fiber bundle-   102 first nip rolls-   104 tension roll-   106 second nip rolls-   108 air feeder-   110 oil applicator-   112 dust adsorbent oil bath-   114 third nip rolls-   115 opening facilitator-   116 edge-   117 upstream portion-   118 downstream portion-   119 a first surface-   119 b: second surface-   120, 122, and 150 nonwoven fabric roll-   121, 123, and 151 belt-shaped nonwoven fabric-   124, 126, and 152 dancer roller-   128, 132, 136, 138, 140, and 156 merging point-   130 gather cutter-   134 second melt bonding apparatus-   154 gather roll-   158 first melt bonding apparatus-   160 cutter unit-   201 widening member-   202 curved portion

The invention claimed is:
 1. A method of continuously producing anopened fiber bundle for a cleaning member, the method comprising thesteps of: (a₁) providing (i) first nip rolls rotating at a constantperipheral velocity, (ii) second nip rolls, which are disposeddownstream in a conveying direction from the first nip rolls and have afaster peripheral velocity compared with the first nip rolls, (iii)third nip rolls, which are disposed downstream in the conveyingdirection from the second nip rolls and have a slower peripheralvelocity compared with the second nip rolls, (iv) an air feeder which isdisposed between the second nip rolls and the third nip rolls in theconveying direction, and (v) a widening member disposed downstream inthe conveying direction from the second nip rolls, wherein the wideningmember widens the belt-shaped fiber bundle in a width direction thereofwhile the belt-shaped fiber bundle is in contact with the wideningmember, and the widening member comprises a curved portion downwardlycurved in a thickness direction of the belt-shaped fiber bundle; (a₂)conveying a fiber bundle in the conveying direction using the first niprolls and the second nip rolls to apply a tensile force to the fiberbundle between the first nip rolls and the second nip rolls so that thefiber bundle is extended; (a₃) conveying the fiber bundle furtherdownstream in the conveying direction using the second nip rolls and thethird nip rolls, which have the slower peripheral velocity compared withthe second nip rolls, to relax the fiber bundle by relieving the tensileforce and to widen the fiber bundle, thereby forming a belt-shaped fiberbundle; and (a₄) blowing air from the air feeder in a directionintersecting with the conveying direction of the belt-shaped fiberbundle.
 2. A method of continuously producing an opened fiber bundle fora cleaning member, the method comprising the steps of: (a₁) providing(i) first nip rolls rotating at a constant peripheral velocity, (ii)second nip rolls, which are disposed downstream in a conveying directionfrom the first nip rolls and have a faster peripheral velocity comparedwith the first nip rolls, (iii) third nip rolls, which are disposeddownstream in the conveying direction from the second nip rolls and havea slower peripheral velocity compared with the second nip rolls, and(iv) an air feeder which is disposed downstream in the conveyingdirection from the second nip rolls, between the second nip rolls andthe third nip rolls; (a₂) conveying a fiber bundle in the conveyingdirection using the first nip rolls and the second nip rolls to apply atensile force to the fiber bundle between the first nip rolls and thesecond nip rolls so that the fiber bundle is extended; (a₃) conveyingthe fiber bundle further downstream in the conveying direction using thesecond nip rolls and the third nip rolls, which have the slowerperipheral velocity compared with the second nip rolls, to relax thefiber bundle by relieving the tensile force and to widen the fiberbundle, thereby forming a belt-shaped fiber bundle; and (a₄) blowing airfrom the air feeder in a direction intersecting with the conveyingdirection of the belt-shaped fiber bundle, wherein said providingfurther includes providing an opening facilitator disposed between thefirst nip rolls and the second nip rolls, said opening facilitatorincludes an edge extending orthogonal to the conveying direction, anupstream portion adjacently located upstream from the edge, and adownstream portion adjacently located downstream from the edge, thefiber bundle is pushed onto the upstream portion and the edge of theopening facilitator while being conveyed in the step (a₂), and the step(a₂) comprises conveying the fiber bundle in a first direction along theupstream portion of the opening facilitator, and then conveying thefiber bundle in a second direction along the downstream portion of theopening facilitator, the second direction different from the firstdirection.
 3. The method according to claim 2, wherein after the fiberbundle runs through the edge, the fiber bundle is conveyed along thedownstream portion of the opening facilitator.
 4. The method accordingto claim 2, wherein the opening facilitator is static.
 5. The methodaccording to claim 1, wherein the belt-shaped fiber bundle is conveyedand widened while contacting with the curved portion.
 6. The methodaccording to claim 2, wherein an angle between the first and seconddirections is in a range of 30° to 150°.
 7. The method according toclaim 2, wherein fibers located at a first surface of the fiber bundleare in direct contact with the opening facilitator, and fibers locatedat a second surface, opposite the first surface, of the fiber bundletravel, at the edge of the opening facilitator, over a longer distancethan the fibers at the first surface of the fiber bundle.
 8. The methodaccording to claim 2, wherein the step (a₂) comprises the conveying thefiber bundle in the second direction is such that the fiber bundle isconveyed along but spaced away from the downstream portion of theopening facilitator.
 9. The method according to claim 1, wherein thestep (a₁) further comprises providing tension rolls between the firstnip rolls and the second nip rolls in the conveying direction, and thetension rolls gradually increase the tensile force applied to the fiberbundle.